Film-based battery holder

Abstract

A battery pack is provided. The battery pack includes a first battery that includes a first terminal and second terminal on the opposite side of the battery from the first terminal. The battery pack further includes a battery holder. The battery holder includes a flexible substrate and a first conductive element disposed on the flexible substrate. The first conductive element has a first contact region to electrically engage with the first terminal. The battery holder further includes a second conductive element that has a second contact region to electrically engage with the second terminal when the flexible substrate is folded over the first battery.

What is claimed is: 
     
         1 . A battery holder for retaining a first battery having a first terminal and a second terminal on an opposite side of the battery from the first terminal, the battery holder comprising:
 a flexible substrate;   a first conductive element disposed on the flexible substrate, the first conductive element having a first contact region to electrically engage with the first terminal; and   a second conductive element having a second contact region to electrically engage with the second terminal when the flexible substrate is folded over the first battery.   
     
     
         2 . The battery holder of  claim 1 , wherein the first conductive element and second conductive element are formed of conductive ink; and
 the battery holder further includes an adhesive disposed adjacent to the first trace and second trace.   
     
     
         3 . The battery holder of  claim 1 , wherein the first conductive element is electrically isolated from the second conductive element. 
     
     
         4 . The battery holder of  claim 1 , wherein the battery holder is further configured retain a second battery having a third terminal and fourth terminal;
 the battery holder further comprising:
 a third conductive element disposed on the flexible substrate, the third conductive element having a third contact region to electrically engage the third terminal. 
   
     
     
         5 . The battery holder of  claim 4 , wherein the third conductive element is disposed on the same side of the flexible substrate as the first conductive element. 
     
     
         6 . The battery holder of  claim 4 , further comprising a fourth conductive element disposed on the flexible substrate, the fourth conductive element having a fourth contact region to electrically engage the fourth terminal. 
     
     
         7 . The battery holder of  claim 6 , wherein the first conductive element is electrically connected to the fourth conductive element; and
 the third conductive element is electrically connected to the second conductive element.   
     
     
         8 . The battery holder of  claim 6 , wherein the flexible substrate has a first side and a second side opposite the first side, the first, second and third conductive elements being disposed on the first side, the fourth conductive element being disposed the second side. 
     
     
         9 . The battery holder of  claim 1 , wherein the first conductive element and second conductive element are formed of conductive epoxy. 
     
     
         10 . The battery holder of  claim 1 , wherein the first conductive element is electrically isolated from the second conductive element. 
     
     
         11 . The battery holder of  claim 1 , wherein the first conductive element includes a first metal grommet distal the first contact region; and
 the second conductive element includes a second metal grommet distal the second contact region.   
     
     
         12 . A battery pack, comprising:
 a first battery, the first battery including a first terminal and second terminal on the opposite side of the battery from the first terminal;   a battery holder, the battery holder including:
 a flexible substrate; 
 a first conductive element disposed on the flexible substrate, the first conductive element having a first contact region to electrically engage with the first terminal; and 
 a second conductive element having a second contact region to electrically engage with the second terminal when the flexible substrate is folded over the first battery. 
   
     
     
         13 . The battery pack of  claim 12 , wherein the first conductive element and second conductive element are formed of conductive ink; and
 the battery holder further includes an adhesive disposed adjacent to the first trace and second trace.   
     
     
         14 . The battery pack of  claim 12 , wherein the first conductive element is electrically isolated from the second conductive element. 
     
     
         15 . The battery pack of  claim 12 , wherein the battery holder is further configured retain a second battery having a third terminal and fourth terminal;
 the battery holder further comprising:
 a third conductive element disposed on the flexible substrate, the third conductive element having a third contact region to electrically engage one of the third terminal and fourth terminal. 
   
     
     
         16 . The battery pack of  claim 15 , further comprising a fourth conductive element disposed on the flexible substrate, the fourth conductive element having a fourth contact region to electrically engage one of the third terminal and fourth terminal. 
     
     
         17 . The battery pack of  claim 16 , wherein the flexible substrate has a first side and a second side opposite the first side, the first, second and third conductive elements being disposed on the first side, the fourth conductive element being disposed on the second side. 
     
     
         18 . The battery pack of  claim 12 , wherein the first conductive element and second conductive element are formed of conductive epoxy. 
     
     
         19 . A method of assembling a battery pack from a flexible substrate including at least a first conductive element having a first contact region and second conductive element having a second contact region, the method comprising:
 positioning a first battery having a first terminal and second terminal on the first contact region, the first terminal electrically engaging the first contact region; and   folding a portion of the flexible substrate including the second conductive element over the first battery to electrically engage the second terminal with the second conductive element.   
     
     
         20 . The method of  claim 19 , wherein the flexible substrate includes a third conductive element having a third contact region and fourth conductive element having a fourth contact region; and
 the method further includes:
 positioning a second battery having a third terminal and fourth terminal on the third contact region, the third terminal electrically engaging the third contact region; 
 folding another portion of the flexible substrate including the first, second and fourth contact regions over the second battery to electrically engage the fourth terminal with the fourth contact region.